Safety Helmet

ABSTRACT

The present invention provides a protective helmet to protect the wearer from a brain injury when engaged in a contact sport. The helmet comprises an outer shell formed as a sandwich comprising outer and inner impact resistant non-fracturing layer which encases an intermediate layer made of a resilient gel layer, carbon fiber layer and disjoined stack member layer. The inner wall of the inner impact resistant layer further comprises a plurality of disjoined gel patches attached thereon.

BACKGROUND OF THE INVENTION

The present invention relates to protective head gear more specifically a helmet internally layered with resilient shock absorbing gel material.

Most helmets consist of a single shell that is filled with padding. Some designs have added layers of shock absorbing gel to help the padding to absorbing shock. The head is probably one of the most vulnerable parts of the human body during a crash accident or a hard fall. All helmets attempt to protect the wearer's head by absorbing mechanical energy and protect against penetration. An anatomical design is used to dissipate impact energy over the entire helmet and prevent debris from puncturing the head. There are several designs of helmets and some have attachments such as face visors, google, or small face cages. Designs are specifically engineered to protect wearer based upon a specific sport (i.e. basketball, football), construction, motorcycle driving, or car racing.

In prior art, protective headgears are comprised of outer shells that are constructed of hard durable material such as plastic wherein an inner shell comprised of a foam type of material is attached to the hard outer shell. For example, in patent 4060855, the invention discloses a pad structure as a protective headgear made of resilient foam and comprises a jaw pad. In patent 7832023, the invention disclosed has a load spreading profile that is attached to a rigid outer shell.

It is to be noted that no helmet can totally protect against injury. However, the design of the present invention is an improved design over the prior art that helps protect the wearer against serious head injuries specifically concussions.

SUMMARY OF THE INVENTION

One of the main objectives of the present invention is to provide a helmet that absorbs the impact of the

The present invention provides a protective helmet to protect the wearer from a brain injury when engaged in a contact sport. The helmet comprises an outer shell formed as a sandwich comprising outer and inner impact resistant layer with an intermediate layer made of composite foam encased in an absorbing gel. The inner wall of the inner impact resistant layer further comprises a plurality of disjoined gel patches attached thereon.

The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a read in of the following detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention.

BRIEF DESCRIPTION OF DRAWINGS

This invention is described by appended claims in relation to description of a preferred embodiment with reference to the following drawings which are described briefly as follows:

FIG. 1 depicts a side perspective view of the present invention.

FIG. 2 is a cross-sectional view of the present invention.

FIG. 3 is a side cross-sectional view of the present invention.

FIG. 4 is a cut away cross-sectional view of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is a protective helmet. In FIG. 1, the helmet (5) has a standard spheroidal shape with an integrally formed crown region (10), back region (12), front region (13), and opposing sides (14, 15). Crown region (10) sits above the top of the head. Then, front region (13) extends downwardly from crown region (10) to cover the forehead of the wearer. Then, back region (12) extends downwardly from the crown region (10) to the back of the wearer head. Opposing sides (14, 15) extends downwardly from the crown region (10) over the wearer ears. Helmet (5) extends downward around the user's head so that the user's head is completely enclosed and protected from injury. Helmet (5) can be adapted to be used to support any type of helmet for example, motorcycle, sports racing, bicycling, and football.

Referring to FIG. 2, there is shown a cross sectional view of the shell (105) of the helmet. The shell (105) of helmet (5) is formed as a sandwich with an outer (21) and inner (70) impact fracture resistant layer with an intermediate layer (27). Shell (105) has a vertical axis extending downwardly from the crown region (10) and each opposing side (14, 15) lies generally parallel to the longitudinal axis of the helmet shell (5). The shell (105) can be made of varying sizes depending upon the size of the head of the wearer.

Crown region (10) of the shell (105) can have a plurality of ventilation openings or air vents (73) which permit passage of air through shell (105) as shown in FIG. 1. Vents (73) permit air adjunct the head of wearer to pass outwardly through air vents (73) providing greater comfort to the wearer of the helmet (5).

As shown in FIG. 2, there is an outer and inner layer (21, 70) that is made of a light weight high tensile strength impact and fracture resistant material. In the present invention, the outer shell (20) can be composed of a composite aramide fiber such as Kevlar or suitable material. The outer shell (20) has a thickness of 2.5 mm. Other suitable materials can be Dyneema, a composite, carbon fiber, a composite glass fiber or another suitable lightweight fracture resistant high tensile material. The impact resistant material is lightweight and approximately five times stronger than steel.

A layer (80) of shock absorbing resilient material abuts and is lay beneath the outer layer (21). The shock absorbing layer (80) can be composed of an impact resilient gel material such as silicone or another suitable material. The shock absorbing layer (80) has a thickness of 6.5 mm. An inner layer (70) of carbon fiber or a material of similar weight and strength abuts and lay underneath the gel layer (80). The inner layer (70) of carbon fiber has a thickness of 2.5 mm. When an impact occurs, the outer layer (21) flexes into the shock absorbing gel layer (80) wherein the impact is absorbed. In this design, the shock of the impact is absorbed within the gel layer (80) wherein the energy is converted to heat inside the viscous absorbing resilient gel. With the present construction shell (105) design serves to transmit and spread the load or any impact to the inner multi layers absorbing the impact thereby decreasing brain injury.

The outer impact resistant layer (21) and inner impact resistant layer (70) extend from the crown region (10) downwardly from the longitudinal axis (28) to the edge of the front region (13) and back region (12). Each opposing side (14, 15) extends downwardly from the crown region (10) to below the wearer's ear.

Disposed abutting and beneath the shock absorbing gel layer (80) is a carbon fiber layer (71) that extends the length of the circumference of the curve of the shell (105). Carbon fiber or alternatively graphite fiber is a material consisting of fibers composed of mostly carbon atoms. The carbon fibers have a high tensile strength. Low weight, high chemical resistance, high temperature tolerance and low thermal expansion. Carbon fibers are usually combined with other material to form a composite. Normally the carbon fiber is reinforced with a polymer, plastic or thermoplastic. Other fibers can be bonded to the carbon fiber such as aramid, glass or glass fibers. As the inner (70) and outer impact resistant layer (21), the carbon fiber layer (71) extend from the crown region (10) downwardly from the longitudinal axis to the edge of the front region (13) and back region (12). Each opposing side (14, 15) extends downwardly from the crown region (10).

In the illustrated embodiment a stack layer (40) lay beneath and abutting the carbon fiber layer (71). The stack layer (40) has a thickness of 14 mm. As the inner (70) and outer (21), the stack layer (40) extends from the crown region (10) downwardly from the longitudinal axis to the edge of the front region (13) and back region (12). Each opposing side (14, 15) extends downwardly from the crown region (10). In the illustrated embodiment in FIG. 2, the stack layer (40) comprises a plurality of stack members with each having a substantial triangular shape. As depicted, a plurality of disjoined air pocket cell (30) is interspersed adjacent to each stack member (22).

Each stack member (22) comprises a plurality of layers (50, 60) of various densities interdisposed upon each other. In the illustrated embodiment, the various layers comprise closed-cell extruding strips (24) of Styrofoam or carbon fiber. Styrofoam is a trademarked brand of closed-cell extruded polystyrene foam which is typically white and is made of expanded polystyrene beads. It is composed of ninety-eight percent air, making it lightweight and buoyant as well as comprising insulation. The shape of each stack member is not limited to a triangular shape. In the illustrated embodiment stack member layer (50) is superimposed upon stack member layer (60) wherein the Styrofoam acts as insulation for the carbon fiber high tensile strength layer.

There is an innermost layer (26) that is made of Kevlar or similar material. The outer layer (20) and the inner layer (26) of shell (105) create a complete shell (105) that encases the intermediate layer (27). On the inside of the shell (105), there are a plurality of impact gel strips that are placed around the inside of the shell.

It is understood that the invention is not limited to the exact details of construction, operation, exact materials or embodiment shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. 

1. A protective helmet comprising an outer shell formed of multiple layers for the helmet having a spheroid shape with a base opening configured to receive a wearer's head, the outer shell comprising: the outer shell defined by a crown, a front side, and a back side; a longitudinal axis extending vertically downward from the crown to a first side and an opposing side therefrom; the first side lying in opposite parallel planes with the opposing side; a curve with a circumference extending from the first side to the opposing side; an outer layer made of a hard_high tensile strength lightweight impact fracture resistant material extending the length of the circumference of the curve; an inner layer made of a hard_high tensile strength lightweight impact fracture resistant material the extending length of the circumference of the curve; multilayered intermediate layer sandwiched between the outer layer and the inner layer, the multilayered intermediate layer comprised of a shock absorbing resilient material, carbon fiber like layer, and a plurality of disjoined stack composite members; a the carbon fiber like layer abutting beneath the shock absorbent resilient material extending the circumference of the curve; the shock absorbent resilient material abutting beneath the inner surface of the outer layer extending the circumference of the curve; and a plurality of disjoined air pocket cells dispersed between the plurality of disjoined stack composite members abutting beneath the carbon fiber like layer wherein the multilayered intermediate layer is configured to absorb the energy of an impact to the wearers head is absorbed within the intermediate layer of the outer shell thereby decreasing brain injury.
 2. The helmet of claim 1 wherein the outer and inner impact resistant layers are Kevlar, an Ultra-high-molecular-weight polyethylene, or glass fiber.
 3. The helmet of claim 1 wherein the resilient absorbent gel layer is made of silicone.
 4. The helmet of claim 1 wherein the inner layer further comprises an inner surface with a plurality of disjoined resilient gel patches attached thereto.
 5. The helmet of claim 1 wherein the outer and inner impact resistant layer is lightweight and approximately five times stronger than steel.
 6. The helmet of claim 1 wherein the outer and inner impact resistant layer is made of an aramide composite material.
 7. The helmet of claim 1 wherein each stack member of the plurality of stack members further comprise a plurality of layers with varying densities of a carbon superimposed upon a closed-cell extruded polystyrene foam.
 8. The helmet of claim 1 wherein the shock absorbing resilient material is an absorbent gel layer.
 9. The helmet of claim 1 wherein the carbon fiber like layer is graphite fiber.
 10. The helmet of claim 1 wherein the carbon fiber like layer is a composite material.
 11. The helmet of claim 1 wherein the carbon fiber like layer is reinforced with a polymer, plastic material, or thermoplastic material.
 12. The helmet of claim 1 wherein the carbon fiber like layer is bonded with aramid, glass, or glass fibers.
 13. The helmet of claim 1 wherein the stack composite member have substantially a triangular shape.
 14. The helmet of claim 1 wherein the stack layer has a thickness of at least 14 mm.
 15. The helmet of claim 1 wherein the shock absorbing resilient material has a thickness of at least 6.5 mm.
 16. The helmet of claim 1 wherein the outer layer flexes inward upon impact.
 17. A protective helmet comprising an outer shell formed of multiple layers for the helmet having a spheroid shape with a base opening configured to receive a wearer's head, the outer shell comprising: the outer shell defined by a crown, a front side, and a back side; a longitudinal axis extending vertically downward from the crown to a first side and an opposing side therefrom; the first side lying in opposite parallel planes with the opposing side; a curve with a circumference extending from the first side to the opposing side; an outer layer made of a hard high tensile strength lightweight impact fracture resistant material extending the length of the circumference of the curve; an inner layer made of a hard high tensile strength lightweight impact fracture resistant material the extending length of the circumference of the curve; multilayered intermediate layer sandwiched between the outer layer and the inner layer. the multilayered intermediate layer comprised of a shock absorbing gel material, carbon fiber like layer, and a plurality of disjoined stack composite members; the carbon fiber like layer abutting beneath the shock absorbent resilient material extending the circumference of the curve; the shock absorbent gel material abutting beneath the inner surface of the outer layer extending the circumference of the curve; and a plurality of disjoined air pocket cells dispersed between the plurality of disjoined stack composite members abutting beneath the carbon fiber like layer wherein the multilayered intermediate layer is configured to absorb the energy of an impact to the wearers head is absorbed within the intermediate layer of the outer shell thereby decreasing brain injury. 